About Reactor internals

Shell’s latest-generation reactor internals technology is applied to grass-roots units and is used for replacing lower-performing trays in revamps. Shell has over 25 years of operational experience with reactor internals.

The performance of hydroprocessing reactors is determined not only by the catalyst loaded but also by the design of their internals. Shell Global Solutions’ reactor internals technology uniformly distributes liquid and gas, minimises thermal mal-distribution, and maximises reactor catalyst inventory and utilisation. This is critical for applications with more-stringent product specifications, such as ultra-low-sulphur diesel production as well as for the safety and reliability in high reactive feed applications such as C4/C5 and Pygas hydrogenation in petrochemical plants.

About the technology

Shell Global Solutions’ reactor internals have continuously advanced through the use of the organisation’s pressurised testing facilities and advanced computer simulations, and experience from Shell Group (“Shell”) and non-Shell refineries and petrochemical plants. The technology is applied to grass-roots units and for replacing lower-performing trays in revamps. To date, our reactor internals have over 25 years of operational experience and have been designed for over 500 applications, most of which have been for non-Shell customers.

Key characteristics and advantages include:

minimum pressure drop;

full integration with low interbed height, thus a small space requirement;

no liquid-gas distributive packing required;

a robust performance over a wide operating window, including a high tolerance to tray tilt; and

In addition, we provide our customers with tailored design and a range of support services that can include thermocouple advice, complete project management, tray delivery, and on-site installation advice.

Value estimates

What new Shell reactor internals could be worth to you as an operator

Despite the important role that reactor internals play, many refineries may be failing to capture the maximum value from their units. Some of the potential benefits of installing the latest-generation, state-of-the-art Shell reactor internals are quantified below.

Increased cycle life

Latest-generation Shell reactor internals may mean fewer interim shutdowns between major turnarounds. The potential value for a 100-t/h unit that has a total shutdown time of 14 days is $670,000.1

Processing higher-margin feeds

Increased catalyst utilisation enables increased feed severity while achieving the same cycle length. The potential value of increasing the proportion of light cycle oil by just 5% in a 100-t/h unit is some $2.2 million per year.2

Better hydrocracker product yields

Latest-generation Shell reactor internals may enable a higher selectivity catalyst to be installed to produce higher volumes of valuable middle distillates. The potential value for a 200-t/h unit is about $3.5 million per year.3

Shorter turnaround times

Latest-generation Shell reactor internals that are designed for easy access and fast installation could save two days for each turnaround. The potential value for a 100-t/h unit is $96,000 per turnaround.1

Enhanced safety

There are major safety benefits when reactor internals do not require cutting and welding as power tools, welding equipment and hot-work permits are not required. Low maintenance of the reactor internals reduces the confined space residence time. In addition, all Shell Reactor Internals are equipped with manways for easy entry and exit, and quick egress of personnel in the case of an emergency.